TFT panel alignment and attachment method and apparatus

ABSTRACT

A method for aligning a plurality of thin film transistor tiles for constructing a flat panel display. A coverplate is arranged on a coverplate support. A first layer of a bonding material is applied to at least one of a first side of each of the tiles and a surface of the coverplate on which the tiles are to be secured. The tiles are arranged on the coverplate, such that the first layer of bonding material is arranged between the tiles and the coverplate. The tiles are connected to an alignment apparatus. The tiles are aligned relative to each other and the coverplate. The tiles are at least partially secured to the coverplate.

RELATED PUBLICATION

This application contains the same specification and claims as U.S. Pat.No. 5,980,348, which was published by mistake on Nov. 9, 1999 as thepatent was not granted on that date. Additional prior art has beenconsidered and is made of record by way of an IDS statement filed Nov.9, 1999.

FIELD OF THE INVENTION

The invention relates to a method and apparatus for forming a flat paneldisplay by combining a plurality of individual display devices.

BACKGROUND OF THE INVENTION

The size of an individual display device such as a liquid crystaldisplay (LCD) element typically is limited by acceptable manufacturingyields using currently known techniques and tools. It is thereforeadvantageous to be able to combine several display devices together toproduce either a larger display or to mount individual display devicesin various positions on a larger display panel. For example, in thecomputer, television, and entertainment industries, large area displaysof a size much larger than single display device sizes are desired forviewing by groups of people or single individuals. In such applications,close placement and alignment of display devices to each other arecritical parameters in order to make the edges of the display devicesinconspicuous, that is, to ensure no breaks are visible as informationis viewed across the boundaries from display device to display device.Automotive and aircraft dashboard panels may require information such asspeed, temperature, and fuel level to be displayed in various positions,sometimes with large gaps between these positions, on a large overalldisplay panel.

One method of forming a display panel is to clamp individual displayelements between two glass plates using screws or other tighteners andbrackets of various design about the edges of the glass plates.Individual display elements may then be viewed through one of the glassplates. The display can be illuminated, if necessary, by placing a lightsource behind the second glass plate. Such a method is set forth, forexample, in U.S. Pat. No. 4,156,833, the entire disclosure of which ishereby incorporated by reference.

Both the illuminating radiation (hereinafter referred to as “light”) aswell as the display device image must, of necessity, pass through one ormore of the glass plates. Optical properties of the glass plates (suchas the transmission/absorption spectrum, and reflectance properties ofboth surfaces) are important design parameters that can affect displaypanel performance. These parameters can possibly cause reductions inbrightness, contrast, and resolution. Consequently, it is important toselect a glass material and surface treatment with care and to minimizethe number of layers and interference surfaces through which the imagesand illuminating light must pass. Obvious variations of this overallstructure are possible using optically transparent materials other thanglass, such as various plastics, or even opaque materials, for thebackplate in applications where reverse illumination is not needed.

Placing and holding individual display devices in accurate alignmentprior to clamping the glass plates together has been difficult toachieve due to extremely precise requirements on alignment accuracy andthe possibility of shifting one or more devices previously aligned asothers are added prior to clamping all of these in place.

It is also beneficial to provide a seal to prevent dust, moisture,and/or other contaminants, from entering the display panel afterassembly. Including a seal during clamping can add complexity anddifficulty to the clamping process.

Various methods which are the subject of other patents have beendeveloped for making electrical connection to each of the displayelements, or for providing electrical interconnection between these.Connections can be made by overlapping edges of display elements asshown in U.S. Pat. Nos. 5,164,853 and 4,408,836 and Japanese patent JA0302222, or by abutting corresponding conductive pads on edge surfacesof adjacent display elements as shown in U.S. Pat. No. 5,067,021. Theentire contents of the four patents immediately above are herebyincorporated herein by reference. Any of the above or other connectionschemes can be employed in the present invention.

SUMMARY OF THE PRESENT INVENTION

It is an object of the present invention to provide a device foraligning and attaching a plurality of display devices to provide alarger display.

Another object of the present invention is to provide a method foraligning and attaching a plurality of display devices utilizing theapparatus.

In accordance with these and other objects and advantages, the presentinvention provides a method for aligning a plurality of thin filmtransistor display devices or tiles for constructing a flat paneldisplay. A coverplate is arranged on a coverplate support. A first layerof a bonding material is applied to at least one of a first side of eachof the tiles and a surface of the coverplate on which the tiles are tobe secured. The tiles are arranged on the coverplate such that the firstlayer of bonding material is arranged between the tiles and thecoverplate. The tiles are connected to an alignment apparatus. The tilesare aligned relative to each other and/or relative to the coverplate.The tiles are then at least partially secured to the coverplate. Asecond layer of a bonding material is applied to at least one of asecond side of each of the tiles and a surface of a backplate to besecured to the tiles. The backplate is arranged on the tiles, such thatthe second layer of bonding material is arranged between the backplateand the tiles. The backplate is aligned relative to the tiles. Thebackplate is at least partially secured to the tiles. Then, the firstlayer of bonding material and the second layer of bonding material arefully cured, thereby attaching the tiles to the coverplate, thebackplate to the tiles, and the tiles to each other.

Additional aspects of the present invention provide an apparatus foraligning and attaching together a plurality of thin film transistortiles for constructing a flat panel display. The apparatus includes acoverplate support for supporting a coverplate that the tiles are to beattached to. The apparatus also includes a tile engager, a tile positionalterer and a detector for detecting the position of the tiles relativeto each other and relative to the coverplate. The apparatus furtherincludes apparatus for at least partially securing the tiles to thecoverplate. The apparatus further includes apparatus for at leastpartially securing the tiles to the coverplate. The apparatus furtherincludes a backplate engager for engaging a backplate arranged on thetiles, a backplate position alterer for altering a position of thebackplate, and apparatus for at least partially securing the backplateto the tiles.

Still other objects and advantages of the present invention will becomereadily apparent by those skilled in the art from the following detaileddescription, wherein it is shown and described only the preferredembodiments of the invention, simply by way of illustration of the bestmode contemplated of carrying out the invention. As will be realized,the invention is capable of other and different embodiments, and itsseveral details are capable of modifications in various obviousrespects, without departing from the invention. Accordingly, thedrawings and description are to be regarded as illustrative in natureand not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned objects and advantages of the present invention willbe more clearly understood when considered in conjunction with theaccompanying drawings, in which:

FIG. 1 represents a side view of the embodiment of and apparatusaccording to the present invention; and

FIG. 2 represents a top view of an apparatus according to the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates a side view of an embodiment of an apparatusaccording to the present invention. The embodiment shown in FIG. 1includes a coverplate assembly fixture 1. The assembly fixture acts as asupport for a coverplate 3, which is arranged on the assembly fixture 1.

As the flat panel display device is constructed, the assembly fixture 1will act as a support for the entire device including the individualdisplay tiles and the backplate. The assembly fixture 1 and any elementsof the display arranged on the assembly fixture may be transported by anassembly fixture conveyor 5. The assembly fixture conveyor may beutilized to alter the position of the assembly fixture and the elementsof the display arranged on the assembly fixture.

The present invention may include an assembly fixture elevator 7. Theassembly fixture elevator 7 may be utilized to alter a vertical positionof the assembly fixture 1 and any elements of the display arranged onthe assembly fixture. Any type of apparatus for altering the verticalposition of an element such as the assembly fixture 1 may be utilized inthe assembly fixture elevator according to the present invention. Thoseskilled in the art would be able to determine such a device easily.Accordingly, a detailed description of such device is not includedherein.

The assembly fixture 1 may include means for retaining on the assemblyfixture the coverplate and any elements arranged on the coverplate. Forexample, the assembly fixture may include clamps that retain thecoverplate on the assembly fixture. According to another embodiment, theassembly fixture includes a vacuum source for retaining the coverplateon the assembly fixture.

The assembly fixture 1 may also include means for retaining the tiles orbackplate. For example, the assembly fixture may include swinging vacuumclamps for retaining the tiles and/or the backplate on the assemblyfixture. Such clamps may be especially useful for retaining the tilesand/or backplate during the time between their rough placement andarrangement on the coverplate, in the case of the tiles, or on thetiles, in the case of the backplate, and the time at which the tilesand/or backplate are aligned and attached.

In addition to the above, according to some embodiments, the means forretaining the coverplate, tiles, and/or backplate on the assemblyfixture 1, may only immobilize the coverplate, tiles, and/or backplatein the x and y directions.

The elevator 7 may be utilized to bring the coverplate, tiles, and/orbackplate into a position where tile engaging, supporting, and aligningmeans may engage the tiles. According to one embodiment, the elevatorincludes a motor driven ballscrew to actuate a set of lift posts thatprotrude up through the assembly fixture conveyor to access the bottomof the assembly fixture.

The assembly fixture conveyor may include a variety of means fortransporting the assembly fixture. For example, the assembly fixtureconveyor may include a plurality of rollers. The assembly fixtureconveyor could also include a belt. The conveyor and/or the assemblyfixture could be powered to result in movement of the assembly fixture.

Tiles 13, each of which represents an individual flat panel LCD display,are placed upon the coverplate 3 at the beginning of the process of thepresent invention for forming a larger flat panel display. Bondingmaterial may be applied to the top surface of the coverplate in theorientation illustrated in FIG. 1 and/or the bottom surface of the tilesin the configuration illustrated in FIG. 1. Accordingly, the apparatusaccording to the present invention may include means for applyingbonding material, such as an adhesive, to either the coverplate and/orthe tiles for forming a bond between the coverplate and tiles.

Any type of apparatus may be utilized for dispensing the bondingmaterial. For example, an x-y bonding material dispenser could beutilized. Such a dispenser typically includes two arms that interactwith each other. For example, one arm may ride along the other arm.

The bonding material dispenser typically includes a dispensing nozzlethat may ride along one of the arms. Accordingly, the bonding materialdispenser may dispense bonding material at any point on the surface ofthe coverplate by altering the position of at least one of the arms andnozzle.

The adhesive may be applied and according to any known pattern. Forexample, the bonding material could be substantially uniformly depositedon the entire surface of the coverplate. According to one pattern, thebonding material is applied to the surface of the coverplate in a staror asterisk pattern.

The star pattern may be generated on the coverplate by controlling thepath of the nozzle and the nozzle's on/off control. The star pattern maybe created by depositing bonding material from the nozzle whilesimultaneously moving the nozzle in repeated straight lines, includinghorizonal, vertical, and angled 45 degrees from the horizontal andvertical lines. Such lines of bonding material may be formed such thatthe lines intersect at a point where the center of a tile will bearranged.

The nozzle during such an operation will be on during the movement alongthe lines described above. Otherwise, the nozzle will be off such thatbonding material will not flow from the nozzle. The volume of bondingmaterial that will be dispensed from the nozzle may be a function offlow rate of bonding material from the nozzle. The volume of bondingmaterial that will be dispensed from the nozzle may also be a functionof the velocity of the nozzle as it deposits the lines of bondingmaterial. These parameters may be easily determined through routineexperimentation. Typically, the deposition of the bonding material iscarried out so as to ensure that the entire mating surfaces of the tileand the coverplate are covered with adhesive.

A bonding material may also be applied to the surface of the tiles 13shown in FIG. 1 on the side opposite the coverplate to facilitate theretaining of the tiles by means for engaging, supporting, and altering aposition of the tiles. Therefore, the present invention may includemeans for applying a bonding material to this side of the tiles for thispurpose. Preferably, such means applies a small amount, or dot, of abonding material in the vicinity of the center of each of the tiles.

FIG. 1 illustrates the bonding material 15 between the coverplate andthe tiles.

Examples of bonding materials that may be utilized to secure the tilesto the coverplate include adhesives. Examples of suitable adhesivesinclude LUXTRAK 4031, LUXTRAK 4170 and LUXTRAC 4116, all available fromAblestik Labs, or VLC701, available from Glotrax Incorporated.Preferably, the bonding material is optically clear when cured.

As stated above, the present invention includes means for engaging,retaining, and altering position of each of the tiles. These threefunctions may be carried out by three or more separate means.Alternatively, the means may be combined into one device, such as bybeing connected together.

The embodiment illustrated in FIG. 1 includes a tile chuck 17. The tilechuck preferably includes means for engaging and retaining the tiles.According to one embodiment, the tile chuck includes a vacuum source tohold the tile. However, the present invention may include otherapparatus for holding the tiles. For example, the apparatus couldinclude clamps.

Preferably, the tile chuck is compliant in movements that are notparallel to the upper surface of the tiles and coverplates. In otherwords, preferably, the tile chuck is compliant in pitch, roll, and the zaxis direction. However, the chuck may be under motor control andnon-compliant in directions parallel to the upper surface of the tilesand/or the coverplate. In other words, the chuck preferably under motorcontrol in the x and y and directions and rotationally in the x-y plane.

By permitting the chuck to be compliant in the pitch, ;roll and z axisdirections, the thickness of the tiles and thickness of the bondingmaterial may be absorbed in these compliant directions. As such, thetile engaging, retaining and alignment means may not apply significantforce or any force to the tiles in the compliant directions. On thehand, as stated above, the position of the tile chuck may be altered inthe x and y directions as well as rotationally in the x-y plane.

According to one embodiment, the tile chuck may be moved up to fourinches both in the x and y directions.

Clamps on the assembly fixture, such as the swinging vacuum clampsdiscussed above, may prevent the tiles from moving when unengaged by thetile chuck and when not secured to the coverplate, even at leastpartially.

To help ensure alignment of the tiles with respect to each other andwith respect to the coverplate, the position of the tile chuck may bealtered in the x-y plane. Accordingly, the present invention may includea plurality of means for altering the position of each tile chuck. Forexample, each tile chuck may be controlled by a motor for altering theposition of the tile chuck in the x direction 19 and a motor foraltering the position of the tile chuck in the y direction 21. The tilechucks may also be controlled by a third motor 23 for rotationallyaltering the position of each tile chuck in the x-y plane.

Any motor known to those skilled in the art could be utilized to alterthe position of the tile via the tile chucks. According to one example,piezoelectric motors may be utilized according to the present invention.

To facilitate the detection of the position of the tiles relative toeach other and relative to the coverplate, the tiles and coverplate maybe provided with fiducial marks. At least one fiducial mark may beincluded on each tile as well as on the coverplate. According to oneembodiment, each tile may include two fiducial marks. According to oneembodiment, the fiducial marks are small round dots.

According to one embodiment, the fiducial marks on the coverplate aresmall round dots while the fiducial marks on the tiles are small rings.This embodiment typically includes at least one dot on each tile or onthe coverplate in each area covered by a tile and a circle on the eachtile or the coverplate in a corresponding location. According to such anembodiment, the rings may have an internal diameter slightly larger thanthe outer diameter of the dots. The tiles are positioned relative to thecoverplate by positioning the dots within the rings.

The alignment of the tiles relative to each other and relative to thecoverplate may be determined by cameras. Accordingly, the presentinvention may include at least one camera 25 for determining a positionof the fiducial marks on the tiles relative to each other and/orrelative to fiducial marks on the coverplate. According to oneembodiment, the present invention includes at least one camera arrangedin association with each tile.

The embodiment shown in FIGS. 1 and 2 includes two cameras associatedwith each tile and tile chuck. The camera(s) may be mounted on the chuckassembly as in the embodiment shown in FIGS. 1 and 2. The cameras may befocusable on the fiducial marks on the coverplate and the tiles.

According to one embodiment, the cameras are moved up and down.According to another embodiment, the cameras include focusing objects toaccomplish this task. A variety of cameras may be utilized according tothe present invention. For example, one embodiment of the presentinvention includes CCD cameras. The position of the cameras relative tothe tiles may be altered, depending upon the size of the tiles andultimate size of the display being formed with the apparatus.

The present invention may include a computerized control for controllingmovement of the chucks and, hence, the tiles. The computerized controlmay also control focusing of the camera(s). Along these lines, once therelative positions of the fiducial marks on the tiles and/or thecoverplate are determined, the control system may determine the correctamount of movement in the x, y and theta directions for each tilenecessary to cause the tiles to move to the proper location.

The tiles may be moved one at a time. Alternatively, two or more tilesmay be moved simultaneously. After the tiles are moved, the alignment ofthe tiles and/or coverplate may again be checked utilizing thecamera(s). If necessary, one or more of the tiles may again be moved toensure that they are aligned within a desired tolerance. The alignmentverification and processes may be carried out as many times as necessaryto ensure alignment of the tiles and coverplate.

According to the embodiment that includes the dot and circle fiducialmarks, the tiles are arranged such that the fiducial marks on thecoverplate and the tiles are aligned so as to be coaxial within atolerance of ±0.0005 inch, or is whatever tolerance is dictated by thegeometry of the pixels and/or grid pattern.

To facilitate alignment of the tiles and coverplate, at least one lightsource may be arranged on an opposite side of the tiles and coverplatefrom the camera(s). By arranging a light source in such a manner, alight source may provide back illumination to yield a high contrastimage of the fiducial marks on the coverplate and tiles. The apparatusof the present invention may include a plurality of light sources toilluminate various portions of the tiles and coverplate.

Once the tiles are properly aligned relative to each other and relativeto the coverplate, the tiles may be at least partially secured to thecoverplate. The at least partial securing may be accomplished by atleast partially curing at least a portion of the bonding materialbetween the tiles and the coverplate. How the at least partial curing iscarried out may depend upon the type of bonding material being utilized.For example, the bonding material may be curable with ultraviolet light.According to such an embodiment, the apparatus according to the presentinvention may include at least one source of ultraviolet radiation forcuring the bonding material. To accomplish the at least partial securingof the tiles to the coverplate, the bonding material may be spot curedin at least one location between each tile and the coverplate.

As illustrated in FIGS. 1 and 2, the present invention may include atleast one source of ultraviolet radiation 66, including a light guide.

According to one embodiment, the present invention includes a pluralityof UW light sources/guides 66 mounted outside the perimeter of the tilesto conduct ultraviolet radiation onto spots that will fall outside ofthe viewing area of the display panel when the display panel iscompleted. Although the bonding material may be fully cured at a latertime, it may still necessary to spot cure the bonding material so as tohelp stabilize or immobilize the tiles relative to the coverplate.Preferably, if partial spot curing is utilized to partially secure thetiles to the coverplate, the spot curing is carried out outside of thefunctional area of the display panel since a halo of partially curedbonded material may result around the area of spot curing. Such haloareas would be objectionable if they fell within the viewing area of thefinished display. However, if means and/or bonding material(s) are knownor developed that would not produce such a halo, the spot curing maytake place anywhere on the tiles.

Additionally, the bonding material may be curable in another manner. Forexample, the bonding material may be heat curable. Accordingly, theinvention may include means for applying heat to spot cure the bondedmaterial. The at least partial curing of a heat-curable bonding materialmay take place outside of the viewable area of the display as well.

The present invention may also include any other means for at leastpartially curing the bonding material.

After the tiles are at least partially secured to the coverplate, abackplate may be secured to the tiles. The backplate may be arranged onand secured to the tiles with a separate apparatus. The apparatus shownin FIGS. 1 and 2 may also be utilized.

Prior to attaching the backplate, a bonding material is applied to thesurface of the tiles opposite the coverplate and/or the surface of thebackplate that is to be secured to the tiles. Accordingly, an apparatusaccording to the invention may include means for applying a bondingmaterial to the tiles and/or the backplate. The apparatus for applyingbonding material to the tiles and/or backplate may be the same apparatusthat is used for applying bonding material to the tiles and/orcoverplate.

After application of the bonding material, the backplate may then bearranged on the tiles just as the tiles were arranged on the coverplate.

The backplate may then be engaged by means for engaging, supporting andaltering the position of the backplate. The means for engagingsupporting and altering the position of the backplate may besubstantially similar to the apparatus as described above for engaging,supporting and altering the position of tiles. In fact, the sameapparatus may be utilized. Alternatively, a single apparatus such asthat described above for engaging, supporting and altering a position ofa single tile may be utilized with the backplate.

Additionally, the operation of the means for engaging, supporting andaltering the position of the backplate may be substantially the same asthe means for engaging, supporting and altering the position of thetiles. In view of the similarity of the apparatus and operation of theapparatus for engaging, supporting and altering the position of thebackplate, to the same apparatus for performing the same function to thetiles, the apparatus and method need not be discussed in further detailhere.

Once the backplate is properly positioned on the tiles, the backplatemay be at least partially secured to the tiles. Just as the tiles wereat least partially secured to the coverplate, the backplate maysimilarly be at least partially secured to the tiles. Just as with thetiles, the at least partial securing may be carried out by at leastpartially curing at least a portion of the bonding material between thebackplate and the tiles. Similar to the at least partial curing of thebonding material between the tiles and the coverplate, if the backplateis secured to the tiles by at least partially securing the bondingmaterial, preferably, the at least partial curing takes place on an areathat will fall outside the viewable area of the display when the displayis completed. Once again, reference is made to the discussion aboveregarding the at least partial securing of the tiles to the coverplateregarding the at least partial securing of the backplate to the tiles.

Once the backplate is at least partially secured to the tiles, thebonding material between the coverplate and the tiles and the bondingmaterial between tiles and the backplate may be fully cured. Preferably,the bonding material in both locations is optically transparent whencured.

After full curing of the bonding material, further operations may becarried out on the completed display. The apparatus of the presentinvention may be included in a system for forming a flat panel displayfrom a plurality of smaller flat panel displays. Such a system isdisclosed in U.S. patent application to the same inventors with the sametitle as this application and having the reference EN 9-97-133 appearingin the lower left corner of the pages of the application. The entirecontents of the disclosure of this application is hereby incorporated byreference.

The present invention also includes a method for aligning a plurality ofthin film transistor display panels or tiles and attaching them to acoverplate for constructing a flat panel display. The method of thepresent invention may be utilized to form relatively large flat paneldisplays from a plurality of smaller panels or tiles. For example, thepresent invention may be utilized to form finished flat panel displayshaving diagonal dimensions of from 32-45 inches. However, the presentinvention may be utilized to form any size display.

The present invention utilizes smaller readily available panels or tilesand aligns or assembles them to produce a seamless display panel of muchlarger size. A grid mask preferably is included in a coverplate glassthat the tiles are attached to. The front mask of grid lines effectivelyhides the seams between the tiles or subpanels. The front mask/gridblocks light from passing through the grid lines, thereby obscuring theseams between the tiles. According to some embodiments, the frontmask/grid may be metallic or polymeric. A bonding material, such as anadhesive is utilized to join the tiles to the coverplate and thebackplate to the tiles. The bonding material should be opticallytransparent or clear when cured.

According to the method, a coverplate is arranged on an assemblyfixture. A bonding material is applied to a surface of the coverplatethat the tiles are to be secured to and/or the surface of the tiles thatare to be secured to the coverplate. The tiles may then be roughlyarranged on the coverplate. According to one embodiment, the coverplateis raised up to the tiles using an elevator.

At this point, with the tiles roughly arranged on the coverplate, thetiles may be in contact with each other or separated by a gap. Accordingto one embodiment, the tiles is are separated from adjacent tiles by agap of about 0.0625 inch. The tiles may be permitted to sit on thecoverplate for a period of time to provide the bonding material withtime to spread out and fill gaps between the tile and the coverplate andhelp prevent the formation of air bubbles between the tiles and thecoverplate.

The period of time over which the tiles and the coverplate approach eachother to arrive at a desired gap may be from about one to about fourminutes for tile having dimensions of about 10 inches by about 12 inchesand utilizing a bonding material having a viscocity of about 1000centipoise.

Prior or subsequent to any settling time, the tiles and coverplate maybe arranged under means for engaging and altering the position of thetiles. The coverplate may be secured to coverplate support prior orsubsequent to placing .tiles on the coverplate. The coverplate may besecured to the assembly fixture with means described above.

After arranging the coverplate and tiles under the tile engaging andposition altering means, the assembly fixture may be engaged by anelevator 4 raising the coverplate and tiles toward the tile engaging andpositioning means. The tiles may then be engaged by the tile engagingand positioning means.

The elevator may raise the coverplate and tiles a sufficient amount tocause the tiles to butt up against the tile engaging and positioningaltering means, thereby applying at least some force to the coverplateand tiles. This force will cause bonding material between the tiles andthe coverplate to spread out between the tiles and the coverplate,between the tiles themselves, as well as out from the periphery of thetiles. This additional force may also reduce the thickness of thebonding material between the tiles and the coverplate. However, sincethe tile engaging and positioning altering means preferably arecompliant in the z axis direction, the amount of force that the elevatormay apply may be limited to the weight of the tile engaging and positionaltering means.

The position of the tiles relative to each other and relative to thecoverplate may now be detected. If necessary, the tiles may be moved soas to align them to the desired tolerance. According to one embodiment,the tiles are aligned so as to be about 0.002 inch apart. Additionallyor alternatively, the alignment may be made such that the pixels of thetiles are aligned to within 0.0005 inch of the grid mask. According toone embodiment, the fiducial marks are a circle and a dot, as describedabove. These marks may be arranged so as to be coaxial within atolerance of ± about 0.00005 inch.

Prior to or after alignment, the separation of the tiles and thecoverplate may be checked and/or altered. For example, the tiles may bepermitted to dwell on the coverplate for a certain period of time asdescribed above. According to one embodiment, prior to the at leastpartial securing, the tiles are separated from the coverplate by athickness of bonding material of about 3 mils.

After alignment, the tiles may be at least partially secured to thecoverplate. As described above the at least partial securing of thetiles to the coverplate may be carried out by at least partially curingthe bonding material between the tiles to coverplate.

After at least partially securing the tiles to the coverplate, the tilesand coverplate may be lowered by the assembly fixture elevator.Alternatively, the apparatus illustrated in FIGS. 1 and 2 may be movedto expose the upper surface of the tiles. Bonding material may then beapplied to the surface of the tiles not secured to the coverplate and/ora backplate to be secured to the tiles.

A backplate may then be roughly arranged on the tiles. At some pointprior to securing of the backplate to the tiles, the backplate may bepermitted to sit on the tiles for a time sufficient to permit thebackplate to settle on the tile and help the adhesive spread across asurface of the tiles and the backplate and to help prevent air bubblesfrom forming in the adhesive.

After arranging the backplate on the tiles, the backplate, tiles andcoverplate may then be arranged under means for engaging and altering aposition of the backplate. The coverplate, tiles and backplate may thenbe vertically moved to engage the backplate engaging and positionaltering means. As described above, the coverplate, tiles and backplatemay be forced against the backplate engaging and position altering meansto help force the backplate towards the tile so as to further helpspread the adhesive and to help ensure an adhesive layer is formed of adesired thickness.

After engagement by the backplate aligner, the position of the backplatemay then be detected and the backplate moved, if necessary, to ensureproper alignment of the backplate relative to the tiles and thecoverplate. The position of the backplate may be determined by fiducialmarks provided on the backplate and the same or additional fiducialmarks provided on the tiles and/or coverplate involved in aligning thetiles and coverplate. Alignment may then be rechecked and, if necessary,the backplate moved again. The alignment and verification of alignmentprocedures may be carried out as many times as is necessary to ensurealignment of the backplate.

Both the tiles and the backplate may be aligned by moving them in afirst direction parallel to the upper surface of the coverplate, inother words, the x or y direction. The tiles and/or backplate may alsobe aligned by moving them in a second direction parallel to the uppersurface of the coverplate and tiles and perpendicular to the firstdirection, in other words, in the other of the x and y directions. Thecoverplate and tiles may also be aligned by rotating in the x-y plane,parallel to the upper surface of the coverplate and/or tiles.

After alignment is ensured, the backplate may be at least partiallysecured to the tiles. As described above, the at least partial securingmay take place by at least partially curing the bonding material betweenthe backplate and the tiles.

After at least partial securing of the backplate to the tiles, thecoverplate, tiles, and backplate may be fully secured to each other. Thefull securing may be carried out by fully curing the bonding materialbetween the tiles and the coverplate and between the tiles and thebackplate. The full curing may be carried out by directing UV radiation,heat, or whatever means are necessary to fully cure the bonding materialtoward the coverplate, tiles, and backplate.

The foregoing description of the invention illustrates and describes thepresent invention. Additionally, the disclosure shows and describes onlythe preferred embodiments of the invention, but as aforementioned, it isto be understood that the invention is capable of use in various othercombinations, modifications, and environments and is capable of changesor modifications within the scope of the inventive concept as expressedherein, commensurate with the above teachings, and/or the skill orknowledge of the relevant art. The embodiments described hereinabove arefurther intended to explain best modes known of practicing the inventionand to enable others skilled in the art to utilize the invention insuch, or other, embodiments and with the various modifications requiredby the particular applications or uses of the invention. Accordingly,the description is not intended to limit the invention to the formdisclosed herein. Also, it is intended that the appended claims beconstrued to include alternative embodiments.

We claim:
 1. A method for aligning a plurality of thin film transistor tiles for constructing a flat panel display, the method comprising the steps of: arranging a coverplate on a coverplate support; applying a first layer of a bonding material to at least one of a first side of each of the tiles and a surface of the coverplate on which the tiles are to be secured; arranging the tiles on the coverplate, such that the first layer of bonding material is arranged between the tiles and the coverplate; connecting the tiles to an alignment apparatus; aligning the tiles relative to each other and the coverplate; and at least partially securing the tiles to the coverplate.
 2. The method according to claim 1, further comprising the steps of: applying a second layer of a bonding material to at least one of a second side of each of the tiles and a surface of a backplate to be secured to the tiles; arranging the backplate on the tiles, such that the second layer of bonding material is arranged between the backplate and the tiles; aligning the backplate relative to the tiles; and at least partially securing the backplate to the tiles.
 3. The method according to claim 2, further comprising the step of: fully curing the first layer of bonding material and the second layer of bonding material, thereby attaching the tiles to the coverplate, the backplate to the tiles, and the tiles to each other.
 4. The method according to claim 2, wherein the first layer of bonding material and t he second layer of bonding material are optically transparent when cured.
 5. The method according to claim 2, wherein the backplate includes at least one fiducial mark and the step of aligning the backplate includes the steps of: determining relative positions of the fiducial marks on the backplate, the tiles, and the coverplate relative to each other; and moving the backplate to cause the fiducial marks to move to a predetermined location relative to each other, if necessary.
 6. The method according to claim 2, wherein at least partially securing backplate to the tiles includes the step of: curing at least a portion of the second layer of bonding material between the backplate and each of the tiles.
 7. The method according to claim 2, wherein the first layer of bonding material and the second layer of bonding material are curable with ultraviolet radiation.
 8. The method according to claim 1, wherein the tiles are connected to th e alignment apparatus through a vacuum connection.
 9. The method according to claim 1, wherein each of the tiles and the coverplate include at least one fiducial mark a nd the step of aligning the tiles includes the steps of: determining relative positions of the fiducial marks relative to each other; and moving the tiles to move the fiducial marks to a predetermined location relative to each other, if necessary.
 10. The method according to claim 9, wherein the tiles are aligned utilizing at least one video camera arranged on one side of the tiles, and wherein a light source is mounted on a side of the tiles opposite the at least one video camera, the light source illuminating at least the fiducial marks.
 11. The method according to claim 1, wherein at least partially securing the tiles to the coverplate includes the step of: curing at least a portion of the first layer of bonding material between each of the tiles and the coverplate.
 12. The method according to claim 11, wherein the cured portion of the first layer of bonding material is arranged at a portion of a perimeter of each of the tiles that will be outside a viewing area of the display.
 13. The method according to claim 1, wherein the tiles are aligned to within 0.0005 inch of each other.
 14. The method according to claim 1, wherein the tiles are aligned utilizing at least one video camera.
 15. The method according to claim 1, wherein during the alignment the tiles are only moved in a plane parallel to an upper surface of the coverplate.
 16. The method according to claim 15, wherein the movement of the tiles is in a first direction parallel to an upper surface of the coverplate, a second direction parallel to the upper surface of the coverplate and perpendicular to the first direction, and a rotational direction parallel to the upper surface of the coverplate.
 17. The method according to claim 1, wherein the display includes four tiles.
 18. The method according to claim 1, further comprising the step of: applying pressure to at least one of the tiles and the coverplate to force bonding material between the tiles prior to at least partially securing the tiles to the coverplate.
 19. An apparatus for aligning and attaching together a plurality of thin film transistor tiles for constructing a flat panel display, the apparatus comprising: a coverplate support for supporting a coverplate that the tiles are to be attached to; a tile aligner; a tile position detector for detecting a position of the tiles relative to each other and relative to the coverplate; and apparatus for at least partially securing the tiles to the coverplate.
 20. The apparatus according to claim 19, further comprising: a backplate aligner; and apparatus for at least partially securing the backplate to the tiles.
 21. The apparatus according to claim 20, wherein the apparatus for at least partially securing the tiles to the coverplate is also for at least partially securing the backplate to the tiles.
 22. The apparatus according to claim 20, further comprising: apparatus for fully securing the tiles to the coverplate, wherein the apparatus for fully securing the tiles to the coverplate also fully secures the backplate to the tiles.
 23. The apparatus according to claim 19, wherein the tile aligner includes a vacuum source for engaging and retaining the tiles on the tile aligner.
 24. The apparatus according to claim 19, wherein the tile aligner includes: a tile chuck for engaging each of the tiles; a first tile positioner for separately altering a position of each tile chuck in a first direction parallel to an upper surface of the coverplate; a second tile positioner for separately moving each tile chuck in a second direction parallel to the upper surface of the coverplate and perpendicular to the first direction; and a third tile positioner for separately rotating each tile chuck in a plane parallel to the upper surface of the coverplate.
 25. The apparatus according to claim 24, wherein the chuck freely moves in all directions other than parallel to the upper surface of the coverplate.
 26. The apparatus according to claim 19, further comprising: a coverplate positioner for altering a position of the coverplate support in a direction perpendicular to an upper surface of the coverplate.
 27. The apparatus according to claim 19, wherein the tile position detector includes at least one camera for detecting fiducial marks on the tiles and on the coverplate and at least one light source for illuminating at least the fiducial marks.
 28. The apparatus according to claim 27, further comprising two video cameras for aligning each tile.
 29. The apparatus according to claim 19, wherein the tile aligner is also for aligning the backplate after the at least partial securing of the tiles to the coverplate.
 30. The apparatus according to claim 19, further comprising: apparatus for fully securing the tiles to the coverplate.
 31. The apparatus according to claim 19, wherein the apparatus for at least partially securing the tiles to the coverplate includes apparatus for at least partially curing a first layer of bonding material arranged between the tiles and the coverplate.
 32. The apparatus according to claim 31, wherein the at least partially cured portion of the first layer of bonding material is arranged at a portion of a perimeter of each of the tiles that will be outside a viewing area of the display. 